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In this video I show more techniques for 3D printed sheet metal press forming tools. I improve over my previous designs by making a tool with a moving action as well as fixing a major design flaw. I also demonstrate a more complicated forming operation with many features made in one pressing.
These videos usually take a ton of work and a lot of money in tools and materials. I've made a patreon if you're interested in supporting the creation of these projects: / stuffmadehere
If you missed it, you can find part one here:
• Bending Steel With Pla...
Here's some of the tools that I use in this video + recurring favorites:
Hypertherm powermax 45xp with machine torch: amzn.to/2zfoyAv
Hypertherm fine cut consumables (great for sheet metal) amzn.to/34SjMom
Vise brake (highly recommend): amzn.to/3akCkhZ
Wera allen keys 1000x better than el cheapos: amzn.to/2KlCb36
Wera allen keys (english): amzn.to/2RQUxNG
The best marker ever. Always in my pocket: amzn.to/3ewHGtL
Formlabs Form 3: formlabs.com/3d-printers/form-3/
Ah yes, another episode of this young Tony.
KaletheQuick thought the same😂instantly subbed
Lmao.
High praise indeed.
Ca Lem is this young tony his has the same mill and makes parts more accurately than tony go check him out.
I’m not ever lying, just laughed hard out load like really hard that I you for this. And great video
BRO! I print a ton of tooling for sheet metal and castings but your little dual-barrel hinge thing is sooooo clean!! I'm totally stealing it. thanks man. I owe you one. Thanks for teaching me.
Really cool - I'd love to see examples if you have anything to share. It seems like a really useful technique but not a lot of stuff published on it
That rotary tool when you’re looking at was developed a Curtiss Wright aircraft manufacturing before world war two it’s even documented in some of their shop manuals you kids just have to start reading history books more!!!
@@mitchmonnett468 give me a list of books. Just telling me to read more, not super helpful gramps
@@jacquesplante9287 thank you
@@PeterDiCapua machinery handbook
11:53 "These turned out grate"
leave
when you use the wrong great
@@PlayFull_Cat1 when you don’t get the joke
“So it turned out that it didn’t work because I did it wrong”
That is life.
I subbed right here...
Story of my life...
@@Aethelbeorn AA
Me coding
Dad comes in: So, Stuff Made Here, you got that part to fix my $20 tool yet? Stuff Made Here: Sure, here's a few hundred of them.
Dad: "Are you winning son?" Stuff Made Here: "Define winning" Dad: "Did you accomplish what you set out to do?" Stuff Made Here: "Yes" Dad: "Wait...why did you make me define it?" Stuff Made Here: "Because the raw material cost greatly exceeded the cost of the part, not to mention the sweat equity" Dad: "All I want is what is best for you, I love you son" Wow, that ended differently than I thought it would, and I'm the one who wrote it.
@@bellendbill6227 lmao
I think it's totally awesome. And that this young man is so very brilliant. I am so jealous of his talent. Yea you may not go to this much trouble and cost to make a 2 dollar part for a 40 dollar tool. But....there are always those unobtainable parts at any price.so being able to produce one yourself is priceless..
Surely his dad calls him Stuff Made Here and there is nothing anyone can say to change my mind
I'd bet that it's now closer to a $200 part after all that prototyping. Would love to know the actual total cost.
When you showed how the part was it's own spring I said "oh that's so cool!" out loud, and now my wife thinks I'm even more boring.
worth it.
When you're cutting them out, start the plasma arc in the middle of the waste material and then move to the cut line. That should give you a cleaner cut.
He knows. The issue is the power level and speed for this particular material and thickness. And possibly uneven surface finish on galvanized part.
@@movax20h I still think GrimResistance is right, look at the cuts, he starts and ends them on the edge of the part on the same spot. Offcourse its going to leave a rough spot on the start and endpoint, he could atleast solve that problem by changing settings i think.
@@mick0matic yes you are right, one should start from inside of the waste material, far from final edge. But you can see that the main issue is power level and speed, because even whole edges and holes that had constant feed, had these issues, not just the starting point.
@@movax20h Yes thats true, i only mentioned it so it can atleast be a bit better than what it was before, still its not perfect. Gotta use the tools you have to make the best out of the situation right :P
@@mick0matic It's also recommended that the cuts be staggered on large cut to blank ratios like this because of the heat-warping. It can help reduce the warping by displacing the heat more evenly. Which may make it sit in the tooling better, resulting in a better finished product.
I've worked for almost 7 years in sheet metal manufacturing. I find it impressive how close to actual tools and methods you are getting with what I assume is no or limited prior knowledge of sheet metal. Your rotary benders are extremely close to commercially available ones.
Massive THANK YOU!!! you have opened my eyes to completely new world of options and ideas. You have five very clear explanation and clear knowhow transfer . Again, MASSIVE THANK YOU.
That's genius for you. Someone who not only understands what he's doing but also has the communicative skills and empathy to understand how to convey and explain these things to another person. A lot of smart people lack the social skills to understand how to explain their ideas at a level others can follow. And end up rambling about specifics without having properly conveyed core principles. Understanding an audience you're talking to. To be able to give them a why, how that actually captures them, which they can follow. He would be a great teacher. But we need this guy in other fields. He can make educational video's, do projects for himselglf and business and probably achieve more than teaching in academics. Being part of a college research lab wouldn't be bad though maybe.
For highly complex parts, you should consider creating (I forget the technical name) holes in the bottom of the dye that can be used to push the part off the dye, like whats used in plastic injection molds. Youd have to add another part to the dye to plug the holes for the release pegs, but I think it would save alot of time removing parts from the dye. Really cool work!
Exactly my thoughts as well.
Dan_The_Burger_Man ejector pins I believe, good suggestions!
Roderick storey check out this great video on injection molding. This is were I picked up that term kzhead.info/sun/hbGjpNGrqWV5pHk/bejne.html
yep... thats the source of all my plastic injection knowledge
@@Mrcaffinebean Ejection port would be more fitting with this idea
I used to build stamping dies for a small shop. Those rotary bits are what we call ready benders. Very handy features
This is honestly incredibly valuable for the 3D printing / machining community. Thank you for doing all of this work for us!
I like that videos like this pull all the industry professionals out of the woodwork. They always give good tips. Super cool video!
These are the kind of videos you can like in the beginning, because you know they'll be good enough for a like anyway.
When I used to work in a factory while going to college, forms were often two steps. However the way they got around that was to have two parts pressed at a time. The result is that you’re getting one part per press. The complex dies often had a mechanism that “ejected” the part by pushing the part up from the bottom, which helped when transferring part one to part two in the die set. Even complicated dies involve multiple steps. If you’re mass producing, at a minimum you want one part per press. Good video!
it's amazing you use a hydraulic press, which usually presses or flattens things to give your items a more 3D shape
As someone who works as a Tool and Die Maker this is very inpresive when it comes to how fast you picked up and corrected your mistakes ! Good Job! And maybe see if you can get some Ejectors of some sort :)
These videos are some of the highest quality, most in-depth, and most watchable engineering videos on KZhead. You cannot change my mind. WHERE HAVE YOU BEEN ALL THESE YEARS? Keep em coming!
I found part 1 and 2 of this series fascinating! I have a 3D printer and have really enjoyed learning how to design things in CAD and then print out stuff that's useful I can use around the house or in my car. Once again, excellent content; you earned a new subscriber.
normally for bent parts you want to anneal them in an oven afterwards, to remove residual stresses when entering the plasticity zone. The annealing process (temperature, timing, and cooling ramping) would depends on the material you have bent. If you don't anneal them, depending how they are loaded in service, they can fail early in fatigue.
I'm not a fabricator but these videos are awesome man! I love ingenuity.
My professor told me spring membranes are formed like this in production. Nice to see some video similar to it. I had initial doubts about the soft plastic forming the much harder steel
The double hinge approach is genius and very satisfying to watch! And I do agree that beeing able to print the tooling instead of maschining it is a lot more accesable. Although I doubt that a lot of people own a 3d Printer and a cnc plasma cutter. But I guess that could either be outsourced or exchanged by an alternative method. Maybe their is a way to stamp the desired form out of the sheet metal?
you can make the plasma cutting machine start the holes for that part from the middle so that you don't get that imperfection
I like what you are doing. I'm a die designer and my work never let me try experimenting with plastic printed parts. On the second die you need a stripper around the punches that are forming the flanges. A stripper holds the part firmly in place before forming is done and holds the part down while the punches are being withdrawn from the part. Keep up the good work!
I've watched enought of your videos to get sheet metal company advertismenst... Such fools, why would I need such service, after aquiring the knowledge you convey
You could add some through holes to the die for ejection pins to pop the part off instead of trying to pry it off. You would need to make the overall size of the die larger than the part so you had something to rest the die on when pressing it out. You could get really fancy and make them spring loaded so the part ejected after releasing pressure form the press. Edit: I noticed after posting this that several other had the same idea. lol
I replayed the clip at 5:55 half a dozen times, each time at a slower playback speed. Super satisfying to watch the fruits of deliberated research and development.
That's some pretty thick steel, nice work! You can also press form speaker grills or perforated mesh shapes. 3D printing is great.
I have a 3D printer of my own and this sparks some ideas. Id love to see more of these 3D printed mold videos!
You’re SO on my level. You’re clever, humble, calm and your wife is equally as delightful. God bless you sir. From Matthew in England.
I am currently working on a design for forming microchip legs to a 90degree angle. I was having trouble with the elasticity of the metal legs and am quite happy having found this.
Never thought a 3d print would be this durable
This is really impressive! Also, you always have band aids or band aid adhesive on your hands so I trust you are a true sheet metal worker!
Where did you come from man? The topics you cover are super interesting (I'm a 4th year mech Eng student) and your videos are also high quality - reminds me of Ben Eater in some ways! Great work. :)
Awesome video! I love the focus on iterative design, and you did a great job of explaining the pros / cons of additive vs. machining!
Glad you figured out the clearances... I watched the previous vid and was questioning whether there was adequate clearance for the thickness of the sheet metal.
Nice vid, love the rotary tool/form to get the 90 degree bends, clever!
This video has me looking at some parts I need to build in a entirely new way. Thanks!
That's awesome! I'm amazed by the quality of the parts. Thanks!
That rotating spin thing that forms 90 degree stuff is absolutely genius blew my mind
You can drill holes in the bottom form to push the metal off from underneath with a wooden dowel, or another printed piece to push through multiple holes at the same time!
Really liked the video. You could consider adding 'rejection pins' just like a injection molding machine has. I mean to add holes in tho bottom mold, so you could put pins trough and eject the part. Geep up the good work!
respect for your logical problem solving, persistance in chasing the problem without being over perfectionist
Damn why did it take so long for me to find this channel!?!?!? Such good content
Great work, the reason the first too broke up is due to the same springback as you saw on the first part, the flanges formed will spring back. By reducing the form tool height, there is nothing for the material to grab. Keep up the good work.
The moment you showed your tool at 6:50 I was thinking I've seen that on my espresso machine. Strange how it has a signature look.
This dude is so next level. Blows me away every time
this is amazing. thank you for sharing your experiments and looking forward to seeing more!!
I like how you mix technologies. A lot of people try to use just 3d printing for a project and then get upset because it isn't perfect. 3d printers are just another tool like a mill or plasma cutter.
The Aesthetic of the slightly rough parts is... Kind of industrial and I'm into it.It's so clean and professional, but there's the tiny bit of human crafting to it that makes it feel... Like, personal? I guess? In any case, I love learning from your videos, I like listening to your voice, and I like watching YOU learn at the same time. It's like being invited into the process. Thanks for making these.
This is the video of yours that I stumbled upon where I instantly subscribed. 😎👍💙
Sounds like youre using Inventor. Great tool. Might make a tool like this to sink a countersunk bolt into sheet metal.
For your alignment issue, you can put borders on the lower part that wraps around the upper part so it also aligne the metal part
I am currently working on a press tool prototype. If mine doesn’t work, I am definitely trying your idea with the rotating parts! Really well done. Thanks for the inspiration.
This guy's videos are so high quality. very nice.
Thanks for another excellent of demonstration of using 3d printed parts to form dies. Lots of great ideas to take away.
Awesome, excellent Research & Development!!! I love the people making things just to see what happens and design a thinking path, i really do believe with these actions we get out of the cave after long time
I've experienced this quite a bit. I learned drafting manual drafting in his and 2d cadd early autocad. I've made the transition to solid works because work uses it but have had to relearn drafting with linked stuff like you clearance issues. Then I am a hobby machinist but I'm all manual and work wanted to add additive manufacturing to our setup so again thinking a new way. Wild ride but now I know more things so yah.
I have no idea what he’s doing in any of his videos, but I’m so fascinated that I watch them anyway 😅
I have never been so interested in videos like this before. I have watched all your videos now 😊 thank you stuff made here!
Best way to learn from mistakes. Really like the way you go about stuff. Good work
Wowwww lol it's nice to see someone who uses a press for it's intended purpose (not just smashing, breaking random items haha)
You could print through holes in the form so you can push the sheet metal out using a jig with pins
This, or give it a quick blast through these holes with the air gun as not to marr the surface
I hadn't thought of using air channels. Good idea. Given that the parts are 3D printed it should be easy to incorporate several channels that lead to a single air gun blast hole to eject the part. Will try that on future tools!
Can't believe i just found your channel. this is gold mine
Great follow-up. I appreciate it. And you crack me up with your band-aid remnants and residue
Haha I get cut... a lot. I try not to but nothing seems to work. Then when I'm editing the video I'm cringing at all the bandages. Glad you get a kick out of it :)
@@StuffMadeHere so do I brother. I always have cuts, scares and scratches on my hands. And keeping bandaids on the fingers is quite a challenge!
Great second part of this exciting series. I can't wait to see some more inputs from you :)
Prying it out: you could leave a square cut(s) on the 'floor' of the die, running to the edge, then put a block(s) of the size of the cut(s), plus some extra as a 'handle(s)' sticking out of the die. Then just press down on the 'handle(s)' to lever the part out of the die.
fantastic research. you've inspired me to give it a go.
I am so glad I saw your channel if I am to be honest I kept on seeing your basket ball hoop and ignored it. However I found these videos and am glad I saw this. Very cool stuff.
Hi there, this channel was a suggestion and am I glad it was, you have a new subscriber added to your list after seeing a practical solution for making printed parts to make forms for a press, bravo on the use and I look forward to seeing some more of your videos.......Phil 👍
I suggest you leave a slot on two opposing corners to use as "ejection slots", where a tool arm can eject or pry out the formed piece. You could also do this using a through hole in flat sections of your die press and then print the corresponding ejection pins to avoid marring your formed piece.
"This isn't even my final form yet"
Christian furry lol
This brings back memories of my fly press operating days forming channels in 12" × 8" aluminium plate, in cross section the press formed almost a cylinder like the letter Omega. A few hundred of those and my arms ached like mad. The gorilla bicep machine.
Very informative video, earned my sub. looking foward to more great content like this!
Very cool, not to mention you can even make a hydrolic press out of an old 20 ton jack if you're just starting out with sheet metal stamping. A start up cost of only about $500 at the cheapest.
That rotating die idea is brilliant! 👍
This video well help open a whole new world for makers. Well done!
These two pressing videos are he first two vides i watch from your channel. Very interesting and entertaining. I work as a design engineer and designs productions machines towards the med-tech industry so designing and produce parts is my day job. The funny thing with your iterations it that they follow my mind exactly, When you do each test and get the result, my mind goes, hmm, maybe i should have tried to do this instead, and the next step is you doing exactly that, the same idea that i had. One idea that would be fun to see you try is to shape the edge at the samt time. So you get fillets all round the edges and an more rigid/stable part. By doing so you can make a recess that you fit the plate in to align it, then when you press it goes down into the form, forms the metals with rounded edges and it should be no problems to remove it. You might also be able to combine it with the rolling molds to make sharp 90° edges all around at once, That would be really impressive. Keep up with vids, I love them, The deeper and nerdier, the better :)
I just bought the same espresso machine! Absolutely love it.
If you want to remove the drip tray part from the tool, you could either try to cool the mold or heat the part. The part is metal, so it might be easier to heat that without transferring that heat into the mold, but that might be a fine balance to try and strike. You could also just try throwing the whole thing in the freezer, and then pulling it out and hitting it with a hair dryer. The mold and the plastic will both heat up, of coarse, but the metal will get hot much faster than the plastic which might allow it to expand at a faster enough rate that it you might be able to just pop it off at the right moment. You could also try to lubricate the male side of the mold itself with water before starting, then throwing it in the freezer and just allowing the water in between the mold and the part to freeze, expand, and pop the part off pretty uniformly. Kind of like how tiny drops of water seep into the cracks and concrete and cracks it apart, but in a controlled way.
In tool and die making we have multi part tools. Either the inside or outside edge of the tool comes down to pin down the piece before the actual part of the tool applied pressure to form it. On the bottom we had spring loaded pins or even two part lower die to get the part out of the form because they are impossible to pry out by hand. This is my experience from tools made for exhaust parts. And you are right than complex forms and materials need multiple steps. You should also make the tool bigger than the part so you can add either a recess to center the raw part or just pins. You should also add centering pins on the bottom part and holes on the top to align both tools 100% every time.
Ready benders have some very cool engineering :) Good work!
i have designed this style of tooling for a company making wood stoves and gas stoves, it was used in a number of different parts, tens of thousands of parts per year over many years, my tooling was made of different types of tool steel, my design did not use rounded bottoms on the moving parts, the bottom was flat, the holder had the opening with the bottom tapered toward the center, along the center line of the holder were rubber blocks that kept the moving sides opened up past 90 degrees, when you pressed your part and the top tooling reached the bottom it compressed the rubber at the same time the moving sides over bent the part so after spring back you would have a 90 degree bend, as the press moved up the rubber pushed the moving sides up and released the part, so in short the two moving sides rotated on their outer lower corners, a pivot point. hope this is clear as mud lol
Gear is great. Really learning a lot for your videos. Thank you
If you connect the two circles in the centre into a single slot the part will be more rigid (unable to bend along that centreline). Similarly it would be interesting to arrange the slots to eliminate any straight lines. The result should be very rigid. For removing the part, you should look into ejector pins which would allow you to apply an evenly distributed force to remove the part (minimise any twisting/scratching). I really enjoyed this two-parter and would love to see an update in the future.
I love your work. You are so very talented. Thanks for sharing.
In sheetmetal design, there are two ways to get such parts of your tool. One would be mechanical via the tool beeing two-part and having a punch in the middle. Then there is pressurized air. I think for 3D-Printing you can just take out three circles in your tool from which you can press the part out later. These can also be features of the tool itself, just seperated from the rest.
I watched the first video and now this one. I really like what I see and I have learned a few things about my 3D printer! Subbed and rang the bell!
this deserves a sub. EXCELLENT work!!!!!!!
You could use mold keys to help the dyes align perfectly. And waste a little extra material as buffer on the borders of some parts as necessary to keep edges flat. Can always be trimmed after
Nice! Never crossed my mind to use 3d parts in press mold
Those look like rotary benders. I worked for Ready technology (dayton oh) in the early 2000s. We made those. Was my first machining job. The patents are now up and anyone can make them I believe. Great technology. Dan Gargrave started that company I believe. Was owned by the Danly family when I was there .
Nice stuff! Time lapses of the printing process would add some nice b-roll. For alignment, possibly oversize the blank and add registration features.
+1 for the B-roll.
Nice project. The benders are called ready benders. I wonder if you could have a small step between the filet and the knife to relieve the pressure so that extraction is possible.
As a former tool and die maker this was interesting how a hobbyist goes about this sort of thing. I could see using 3d printed plastic in conjunction with machined metal ones being a good option for prototyping.
Yeah I've been thinking about that - basically put the metal where it is really needed such as high wear points or high stress points and let the rest be plastic. I bet that would work well
This is pretty amazing, and will revolutionize stamping technology
If not revolutionize, it should at least decentralize.
@@ColburnFreml yes good point
When you say it worked much better then expected I hear Ben from applied science Awesome videos keep up the good work I’m gonna try this process with al
Seems totally workable with additional refinement.
Coolest thing I've seen all day!